Study on the Numerical Simulation of the Resistance Spot Welding Process of Magnesium Alloy

2011 ◽  
Vol 189-193 ◽  
pp. 3431-3436
Author(s):  
Jun Wang ◽  
Yun Yan Hu ◽  
Hui Xia Wang ◽  
Yu Feng Zhang
Keyword(s):  
Numerical Simulation ◽  
Magnesium Alloy ◽  
Spot Welding ◽  
Pressure Gauge ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Linear Expansion Coefficient ◽  
Welding Quality ◽  
Plate Electrode

Spot welding of magnesium alloy was a complex processes of thermal, electrical, mechanical and metallurgical mutual coupling, meanwhile its’ low melting point, high thermal conductivity, and high linear expansion coefficient increased the welding quality control difficultly. Basing on SYSWELD, a numerical simulation of effects of welding current, welding time, thickness of plate, electrode pressure gauge and size on the nugget shape and welding quality of ZA31B was demonstrated. The relationship between the size of the nugget dimensions and the welding parameters was established by a large number of simulation and experimental study. The experimental results showed that the analogue result was consistent with the test results, and it could be used to guide the actual production.

scholarly journals Numerical Simulation Mode of Spot Contact Welding Processes

2021 ◽  
pp. 85-91
Author(s):  
А.С. Угловский ◽  
И.М. Соцкая ◽  
Е.В. Шешунова
Keyword(s):  
Spot Welding ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Welding Parameters ◽  
Low Carbon ◽  
Detailed Data ◽  
Welding Quality ◽  
Welding Processes ◽  
Contact Welding

Цель рассмотрения численного метода заключалась в получении подробных данных, позволяющих оценить проведение сварочного процесса: изменение объёма сварного шва, радиуса сварного шва, радиуса зоны термического влияния. При проведении моделирования авторами выведены зависимости параметров точечной сварки низкоуглеродистой стали толщиной до 3,2 мм. Данные зависимости будут определять качество сварных швов. Соответствующее сочетание параметров точечной сварки обеспечит прочное соединение и хорошее качество сварки. The purpose of the numerical method consideration was to obtain detailed data allowing evaluating the performance of the welding process: changing the volume of the weld, the radius of the weld, the radius of the weld-affected zone. During the simulation the authors have derived dependencies of the parameters of spot welding of low-carbon steel up to 3.2 mm thick. These dependencies will determine the quality of the welds. The correct combination of spot welding parameters will ensure a firm joint and good welding quality.

scholarly journals Optimization on Spot Weld Parameters in Resistance Spot Welding Process on AISI 304

2021 ◽  
Vol 11 (3) ◽  
pp. 181-185
Author(s):  
Amit Hazari ◽  
Rith Saha ◽  
Bidisha Ghosh ◽  
Debraj Sengupta ◽  
Sayan Sarkar ◽  
...  
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Electrical Current ◽  
Industrial Applications ◽  
Spot Weld ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Weld Time

The spot welding procedure is used in a variety of industrial applications. The most critical elements influencing welding quality, productivity, and cost are the spot welding parameters. This research examines the effect of welding factors such as welding current and welding time on the strength of various welding joint designs. Resistance spot welding (RSW) is used in the automotive industry for manufacturing. This research focused on the optimization of process parameters for resistance spot welding (RSW), as well as the tensile testing and spot weld diameter. The goals of this analysis are to comprehend the physics of the process and to demonstrate the effect of electrical current, weld time, and material type on the resistance spot welding process.

Optimizing spot welding parameters in a sheet metal assembly by neural networks and genetic algorithm

2007 ◽  
Vol 221 (7) ◽  
pp. 1175-1184 ◽  
Author(s):  
M Hamedi ◽  
M Shariatpanahi ◽  
A Mansourzadeh
Keyword(s):  
Neural Networks ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
The Body ◽  
Welding Parameters ◽  
Automotive Body ◽  
Body In White ◽  
Assembly Operations

Deformation of the spot-welded sub-assemblies in assembly operations and the gap between the matching sub-assemblies have been quality concerns specifically in the automotive industry. Overall quality of the car body and its sub-assemblies, apart from quality of each stamped part, depends markedly on the welding process. This paper considers optimization of three important process parameters in the spot welding of the body components, namely welding current, welding time, and gun force. In this research, first the effects of these parameters on deformation of the sub-assemblies are experimentally investigated. Then neural networks and multi-objective genetic algorithms are utilized to select the optimum values of welding parameters that yield the least values of dimensional deviations in the sub-assemblies. Welding sub-assemblies with the optimized set of parameters brought all of them into the tolerance range. The proposed approach can be utilized in manufacturing sub-assemblies that can fit and match better with adjacent parts in the automotive body. It enhances quality of the joint and will result in improving overall quality of the body in white.

scholarly journals Connection Status Research of the Resistance Spot Welding Joint Based on a Rectangular Terminal Electrode

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 659
Author(s):  
Xiaoqi Zhang ◽  
Lingbo Wei ◽  
Guocheng Xu ◽  
Chunsheng Wang
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Process Analysis ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Current Time ◽  
Axis Direction ◽  
Resistance Spot ◽  
Welding Pressure

Rectangular terminal electrode is adopted in this research to conduct a resistance spot welding (RSW) process on stainless steel plate. The connection status of RSW joints under different welding current, time, and pressure were studied, and revealed how the rectangular terminal electrode shape and its dimensions influence the RSW joint dimensions. The process analysis results showed that the RSW nuggets welded with rectangular terminal electrode are normally elliptical in shape, and the dimensions of the long axis direction and the short axis direction have a certain proportion. As the welding current increases, the nuggets dimensions in long direction increase first and then decrease, and the internal grain structure also varies. As the welding time increases, the nugget size in long direction increase first and then steady and rarely splash occurs. As the welding pressure increase, the nugget dimensions in long direction increase first and then decrease, and the splash easily occurs under large welding pressure. However, when the welding pressure is too small, the unique adjacent double fusion nugget formed. By adopting proper welding parameters, the nugget size and quality can be controlled. This provides an important basis for the application of rectangular terminal electrode in RSW welding process.

scholarly journals Comparison between PCA analysis and Grey based Taguchi analysis of TIG welding process parameters on Duplex stainless steel

2021 ◽  
pp. 67-74
Author(s):  
Sandip Mondal ◽  
Goutam Nandi ◽  
Pradip Kumar Pal
Keyword(s):  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Process Parameters ◽  
Gas Flow ◽  
Welding Process ◽  
Principal Component ◽  
Welding Current ◽  
Tig Welding ◽  
Welding Parameters ◽  
Welding Quality

Tungsten inert gas (TIG) welding on Duplex stainless steel (DSS) is more easy, comfortable and useful, if the process is precisely understood and controlled through development of the science & technology. TIG welding on DSS has been performed with the help of specific controlled welding process parameters. Welding quality has been strongly depended on these process parameters. In this study, some valuable welding parameters are chosen. These are welding current, shielding gas flow rate and speed of welding. These process parameters of TIG welding for ASTM/UNS 2205 DSS welds are optimized by using Principal Component Analysis (PCA) method and Grey based Taguchi’s L9 Orthogonal array (OA) experimental plan with the conception of signal to noise ratio (N/S). After that, compression results of above mentioned two analyses of TIG welding process parameters have been calculated. The quality of the TIG welding on DSS has been evaluated in term of ultimate tensile strength, yield strength and percentage of elongation. Compression results of both analyses indicate application feasibility for continuous improvement of welding quality on DSS in different components of chemical, oil and gas industries.

The Influence of Welding Parameters on Effected the Complete for Resistance Spot Welding on Mild Steel

2011 ◽  
Vol 214 ◽  
pp. 113-117 ◽  
Author(s):  
Prachya Peasura
Keyword(s):  
Mild Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Welding Time ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

This research was study the effect of resistance spot welding process on physical properties. The specimen was mild steel sheet metal. The experiments with full factorial design. The factors used in this study are welding current, welding time and electrode force. The welded specimens were tested by tensile shear testing according to JIS Z 3136: 1999 and macro structure testing according to JIS Z 3139: 1978. The result showed that both of welding current, welding time and electrode force had interaction on tensile shear and nugget size at 95% confidential (P value < 0.05). Factors affecting the tensile shear and nugget size are the most welding current 10,000 amp., welding time 10 cycle and electrode force 1 kN. were tensile shear 7.13 kN. and nugget size maximum 6.75 mm. This research can bring information to the foundation in choosing the appropriate parameters to resistance spot welding process.

A Study on Development of the Optimal Neural Network in GMA Welding Process

2014 ◽  
Vol 936 ◽  
pp. 1759-1763
Author(s):  
Qian Qian Wu ◽  
Ji Hye Lee ◽  
Jong Pyo Lee ◽  
Min Ho Park ◽  
Young Su Kim ◽  
...  
Keyword(s):  
Neural Network ◽  
Process Parameters ◽  
Gma Welding ◽  
High Reliability ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Welding Quality ◽  
Optimal Parameters ◽  
On Line

Gas Metal Arc (GMA) welding is considered as a multi-parameter process that it’s hard to find optimal parameters for good welding. To overcome the problem, an artificial neural network based on the backpropagation algorithm was built to realize the relationships between process parameters and welding quality as output parameter. In this study, Mahalanobis Distance (MD) was employed to evaluate the availability of a given welding parameters which was proved to performance well in multivariate statistics. Input parameters such as welding current and arc voltage were chosen due to their significant influence on the welding quality. To improve the precision of given parameters’ evaluation, neural networks with different configurations were verified. The analyses on the measured and predicted MD by the proposed neural network were conducted. The proposed neural network based on the error backpropogation algorithm was proved to have high reliability to evaluate process parameters, which further makes it available in on-line monitoring system.

Preliminary Investigation on Friction Spot Welding of AZ31 Magnesium Alloy

2012 ◽  
Vol 706-709 ◽  
pp. 3016-3021 ◽  
Author(s):  
L.C. Campanelli ◽  
U.F.H. Suhuddin ◽  
Jorge Fernandez Dos Santos ◽  
N.G. Alcantara
Keyword(s):  
Magnesium Alloy ◽  
Spot Welding ◽  
Welding Process ◽  
High Energy ◽  
Az31 Magnesium Alloy ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Friction Stir ◽  
Friction Spot Welding ◽  
Lap Shear

Friction spot welding (FSpW) is a recent solid state welding process developed and patented by GKSS Forschungszentrum (now Helmholtz-Zentrum Geesthacht), Germany. A spot-like connection is produced by means of an especially designed non-consumable tool consisting of pin, sleeve and clamping ring that creates a joint between sheets in overlap configuration through frictional heat and plastic deformation. FSpW offers many advantages over conventional spot joining techniques including high energy efficiency, surface quality and environmental compatibility. Comparing with friction stir spot welding, FSpW produces a weld without keyhole on the surface at the end of the joining process. In the present study, the possibility of joining AZ31 magnesium alloy by FSpW technique was evaluated by using different welding parameters (rotational speed, plunge depth and dwell time), aiming to produce high quality connections. Microstructural features were analyzed by light optical microscope and mechanical performance was investigated by microhardness test and lap shear test. Microstructure analysis revealed that defects free welds could be produced. A slight decrease in grain size of the stir zone was observed causing a slight increase in the microhardness of this region. The preliminary lap shear data demonstrated that the weld strength is comparable to other welding process.

scholarly journals Short-Pulse Resistance Spot Welding of Aluminum Alloy 6016-T4 - Part 1

2021 ◽  
Vol 100 (01) ◽  
pp. 41-51
Author(s):  
ERIC SCHULZ ◽  
◽  
MATTHIAS WAGNER ◽  
HOLGER SCHUBERT ◽  
WENQI ZHANG ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Short Pulse ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Pull Out ◽  
Welding Processes

Short-pulse welding parameters for resistance spot welding (RSW) of aluminum alloy AA6016-T4 using mediumfrequency direct current (MFDC) systems were developed to reduce the heat input required for nugget formation. Optimization of current and time parameters is critical during RSW of aluminum alloys for reducing energy requirements and avoiding weld imperfections, such as solidification cracking and expulsion, while maintaining weld quality, particularly given the high electrical and thermal conductivities of the materials. The welding time and the applied current level of the current pulse were varied systematically for thin sheets (1 mm or 0.04 in.) of AA6016-T4. The quality of the welds was evaluated by pull-out testing, ultrasound testing, and metallography techniques. Simulations of the same welding processes were performed with the finite element-based SORPAS® software. The results showed short-pulse MFDC RSW can reduce the energy required for sound welds in this alloy without requiring an increase in welding current. The simulations and experiments also showed the welding process had distinct weld nugget nucleation and growth phases.

A study on welding quality for the automatic vertical-position welding process based on Mahalanobis Distance method

2018 ◽  
Vol 1 (91) ◽  
pp. 31-40
Author(s):  
B.-J. Jin ◽  
M.-H. Park ◽  
T.-J. Yun ◽  
J.-Y. Shim ◽  
B.-Y. Kang ◽  
...  
Keyword(s):  
Mahalanobis Distance ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Vertical Position ◽  
Welding Quality ◽  
Distance Method ◽  
Arc Voltage ◽  
On Line ◽  
Arc Welding Process

Purpose: The welding quality and reducing production cost could be achieved by developing the automatic on-line welding quality monitoring system. However, investigation of welding fault to quantify the welding quality on the horizontal-position welding has been concentrated. Therefore, MD (Mahalanobis Distance) method on the vertical-position welding process by analysing the transform arc voltage and welding current gained from the on-line monitoring system has been applied. Design/methodology/approach: The transformed welding current and arc voltage data were taken from the experiment whereby the data number was 2500 data/s. The prediction of Contact Tip to Work Distance (CTWD) to gain best welding quality using the waveform variations were then taken from the experimental results. MD was employed to quantify the welding quality by analysing the transformed arc voltage and welding current. Finally, the optimal CTWD setting has verified the developed algorithms through additional experiments. Two kinds of experiments has been carried out by changing welding parameters artificially to verify the sensitivity and feasibility of WQ (Welding Quality) based on the concepts of MD and normal distribution. Findings: The results represented that WQ was fully capable of quantifying and qualifying the welding faults for automatic vertical-position welding process. Research limitations/implications: The arc welding process on the vertical-position compared to a horizontal-position welding is much more difficult because the metal transfer is influenced by the gravity force. To solve the problem, a new algorithm to monitor and control the welding fault during the arc welding process has been developed. Furthermore, optimization of welding parameters for the vertical-position welding process was really difficult to use the developed algorithms because they are only useful in selecting stored data and not for evaluating the effect of the variation of welding parameters on the weld ability. Practical implications: The developed algorithm could be achieved the highest welding quality at 15mm CTWD setting which the welding quality is 99.50% for the start section and 99.68% at the middle section. Originality/value: This paper proposed a new algorithm which employed the concepts of MD (Mahalanobis Distance) and normal distribution to describe a good quality welding.

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